One-piece core manufacturing method for swing bolster and sideframe of lorry

ABSTRACT

An integer cored craftwork of lorry with swing bolster and sideframe includes: a baroque top mold ( 11 ) being located exactly from above to below as sand on the surface of core box being finished to blow. The top mold ( 11 ) is pressed for being buckled on the surface of blowing sand, then a definite journey of pressure quantity is finished downwards, so that the locally even surface of blowing sand is extruded to be a curved shape up to the mustard according to the shape of the baroque top mold ( 11 ). Finally the integer core forming a integrate lumen section of a cast is finished. It provides a slick surface of integer core while improving the inherent quality of cast and easing the work intension.

FIELD OF THE INVENTION

The present invention relates to a one-piece core-making technical method different from core shooting in casting and producing cores, and especially to a one-piece core-making technique for railway truck bolsters and side frame.

BACKGROUND OF THE INVENTION

Bolster and side frame are key parts for running gear of railway truck. The layered and sectioned manufacturing are generally the core-making technique for forming the sand core of core cavity in the process of manufacturing bolster and side frame casts in China, and even throughout the world, as shown in FIGS. 1 and 2.

For adopting the layered and sectioned core-making techniques, the produced bolster and side frame mainly have disadvantages in two aspects:

The first disadvantage: the sand core connection part has uneasily controlled gap due to sand core deformation or edge breakage, as shown in FIG. 5. The gap 3 makes the core cavity form flash, especially flash in the cavities corresponding to the key parts A and B of the bolster and side frame during the casting and shaping processes. And the connection part of the flash and the core cavity easily produces subsurface pores 8 and micro-cracks 7 during the solidification process of casts with flash in core cavity, as shown in FIG. 6. The subsurface pores 8 and micro-cracks 7 are not easily detected by common product test because they locate in the core cavity, i.e. bringing potential danger of quality to products. As the key parts of running gear of railway truck, the bolster and the side frame have the pores and micro-cracks inside cast which act as stress sources under the continuous cyclic stress during the operation of railway truck, and gradually escalate, thus largely shortening the service life of the product, more seriously, micro-cracks gradually escalate and result in breakage of bolsters and side frames which causes railway accident.

The second disadvantage: core chaplet 9 is always used in order to strengthen the sand core location and ensure the cast wall thickness to conform requirement after core setting and before mould assembling when layering and sectioning sand core, and the amount of bolster or side frame used is more than 30, as shown in FIG. 7. The influence of using core chaplet on performance of cast includes following three aspects: firstly, the core chaplet is uneasy to be fused with the cast, thus reducing the useful sectional area of the cast, and producing partial stress to corresponding part, the disadvantage of such stress, more specifically, that the starting point of the micro-cracks gradually escalate under the cyclic stress; only can be tested out by more than millions and even tens of millions of times of fatigue tests; secondly, the surface of the core chaplet easily erodes, and pores are generated during casting, and the plated tin or zinc reacts with molten steel by contacting, making partial cast produce ingredient segregation to form stress source so as to affect performance; thirdly, when in use, the dropped upper mould sand 10 which is squeezed by the core chaplet directly falls into the mould cavity, as shown in FIG. 7, forming sand holes inside or on the surface of the cast, and the sand holes formed on the cavity surface are not easy to be got rid of, leaving potential dangers in operation.

The main disadvantages above mentioned usually arise in railway operation, causing interrupt of railways, and bringing great social and economic losses to railway transportation.

One-piece core making is required in order to eliminate such disadvantages. Common one-piece core-making solution uses core shooter to shoot core. The core shooting technique is usually half-and-half type and horizontal (transverse) mould closing. But the core shooter equipment is complicated, expensive and has high requirements for the power, controlling parts and installation, moreover, the sand core is partially over compacted and non-uniformly compacted, resulting in generation of cracks in cast.

SUMMARY

The object of the present invention is to provide a one-piece core-making technique for railway truck bolster and side frame, which integrates diverse sand cores into a uniform one, i.e. the one-piece core, based on traditional layered and sectioned core-making techniques.

The technical solution of the invention adopts a one-piece core-making technique for railway truck bolster and side frame, comprising the following steps:

A. the sand filling step: filling sand into the one-piece core box cavity with loose pieces placed into position and meanwhile putting in reinforced core bars, with the height of the sand filled appropriately higher than the striking-off surface, and scraping off sand residue after tamping or jolt-ramming, so that the heights of the moulding sand and the core box top surface are the same;

characterized in that it further comprises the following steps:

B. the step of press forming the matched moulds: when the intensity of core sand is still sufficient after sand filling, pressing the upper press mould down on the moulding sand inside the core box under the guidance action, micro-shocking or pressing the upper press mould to buckle it on the sticking-off surface, and proceeding to press down to make the basic surface of the upper press mould adhere closely to the core box top surface, wherein the inner cavity shape of the upper press mould is the curve part to be pressed out, i.e. the shape of the sand core top;

C. the overturning and stripping step: after the basic surface of the upper press mould adheres to the core box top surface, reinforcing the core sand intensity, and overturning the upper press mould and the core box in a tightly locked condition, then stripping with the core box lifted and the sand core enclosed by the loose pieces which are just disposed on the basic surface of the upper press mould;

D. the step of withdrawing the loose pieces: taking out the loose pieces by sliding along the basic surface of the upper press mould;

E. the sand core hardening and coring step: the sand core to be made is supported by the upper press mould after withdrawal of the loose pieces, and carrying on painting and cleaning when it is hardened to a required intensity.

Preferably, the core sand compression strength in step B before the upper press mould is pressed down is less than 0.04 MPa, and after the basic surface of the upper press mould adheres to the core box top surface, the mould can be stripped when the compression strength of core sand is more than 0.06 MPa.

Beneficial effects of the invention are as follows:

1. Diverse sand cores are integrated into a uniform one; the one-piece core-making technique is adopted; the sand core surface is continuous and smooth, and the curved surface is completely connected, the core cavity produced by the one-piece core is smooth, seamless and flat, which effectively avoids the casting fin and joint flash brought about by using diverse composite sand cores.

2. The sand core has good quality, with smooth surface and high precision of dimensions; the use of a large amount of loose pieces can form relatively complicated sand core shapes and have guaranteed quality; compared with the layered core, the sectional area of the one-piece core increases, and correspondingly, the rigidity enhances as well as the deformation resistance.

3. It facilitates the operations required by the technique, i.e. chilling blocks, core rod, exhaust pipe, moulding material such as chrome iron and ore are precisely located according to technical requirement.

4. Uniform compactness: the total volume of the sand core is compressed when the upper press mould presses downwards the striking-off surface and moulds; at the upper part adjacent to the striking-off surface, the total compactness of the one-piece core is uniform, facilitating the moulding of the cast.

5. Simple equipments: a closing device (micro-shock function can be added) is adopted to complete the mould closing for the upper press mould and the core box from top down, which easily realize the mechanical core making.

6. Convenient installation and maintenance: partial modifications or technical adjustments for the products can be easily finished by adjusting the loose pieces, which is flexible and strongly adaptable.

7. the quantity of the core chaplets used is maximally reduced, ensuring the cast effectively using sectional area, preventing the upper mould sand squeezed by the core chaplet and dropped off during mould assembling from directly falling into the mould cavity to form sand holes inside or on the surface of the cast during using the core chaplet, and meanwhile reducing the works to clean the core chaplet itself.

8. The quality of the core cavity surface is improved, and the difficulty in cleaning sand is reduced also.

9. The dimensional precision of the bolster and side frame cavities is improved. As the size of the corresponding position where the product cavity is formed is stable after the sand core is integrated, the wall thickness of the cast is uniform, effectively avoiding the stages generated by using diverse composite sand cores, and further ensuring the performances such as the intensity in use.

DESCRIPTION OF THE ACCOMPANYING DRAWINGS

FIGS. 1 and 2 are schematic illustrations of the railway truck side frame core made by traditional layered and sectioned core-making techniques;

FIGS. 3 and 4 are schematic illustrations of the one-piece core made by the technique according to the present invention;

FIG. 5 is a schematic illustration of the gap present in the connection part of sand cores in traditional layered and sectioned core making techniques;

FIG. 6 is a schematic illustration of subsurface pores and micro-cracks caused by casting fin of the cast;

FIG. 7 is a schematic illustration of sand core falling off by using core chaplet;

FIG. 8 is a flow of the manufacturing technique according to the present invention.

Reference signs: side frame cast 1, “X” sand core 2, sand core gap 3, parting (core) surface 4, “S” sand core 5, casting fin or joint flash 6, microcrack 7, pore 8, core chaplet 9, mould sand 10 squeezed off by core chaplet, upper press mould 11, basic surface 12, core box frame (body) 13, loose piece 14, loose piece 15, core rod 16, sand core 17.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will be further described with reference to the accompanying drawings and embodiments.

According to an embodiment of the present invention, a one-piece core-making technique for railway truck bolster and side frame shown in FIG. 8 as flow diagram, comprises the following steps:

A. the sand filling step: filling sand into the one-piece core box 13 cavity with loose pieces 14, 15 placed into position and meanwhile putting in reinforced core bars 16, with the height of the sand filled appropriately higher than the striking-off surface, and scraping off sand residue after tamping or jolt-ramming, so that the heights of the moulding sand and the core box top surface are the same;

B. the step of press forming the matched moulds: when the intensity of core sand is still sufficient after sand filling, pressing the upper press mould 11 down on the moulding sand inside the core box 13 under the guidance action, micro-shocking or pressing the upper press mould 11 to buckle it on the sticking-off surface, and proceeding to press down to make the basic surface 12 of the upper press mould adhere closely to the core box 13 top surface, wherein the inner cavity shape of the upper press mould 11 is the curve part to be pressed out, i.e. the shape of the sand core top; the range of the upper press mould A is the curve part to be pressed out, L0 is the stroke that the top point of the sand core presses down, L1 is the stroke for forming a part of side circular bead;

C. the overturning and stripping step: after the basic surface of the upper press mould adheres to the core box top surface, reinforcing the core sand intensity, and overturning the upper press mould and the core box 180 degrees in a tightly locked condition, then stripping with the core box lifted and the sand core enclosed by the loose pieces which are just disposed on the basic surface 12 of the upper press mould;

D. the step of withdrawing the loose pieces 14, 15: taking out the loose pieces 14, 15 by sliding along the basic surface 12 of the upper press mould;

E. the sand core hardening and coring step: the sand core to be made is supported by the upper press mould 11 after withdrawal of the loose pieces, and carrying on painting and cleaning when it is hardened to a required intensity, and finally the core is taken out by the hanger or support equipment to a corresponding storage rack ready for use, and the finally formed one-piece sand core is shown in FIGS. 3 and 4.

In step B of this embodiment, for the purpose of facilitating the technique process, the hardness of the sand core is restricted, and the compression strength of core sand before the upper press mould is pressed down is less than 0.04 MPa, after the basic surface of the upper press mould joints with the core box top surface, the compression strength of core sand is strengthened, and the mould is stripped when the compression strength of core sand is more than 0.06 MPa. 

1. A one-piece core-making method for railway truck bolster and side frame, comprising the following steps: A. the sand filling step: filling sand into the one-piece core box cavity with loose pieces placed into position and meanwhile putting in reinforced core bars, with the height of the sand filled appropriately higher than the striking-off surface, and scraping off sand residue after tamping or jolt-ramming, so that the heights of the moulding sand and the core box top surface are the same; characterized in that it further comprises the following steps: B. the step of press forming the matched moulds: when the intensity of core sand is still sufficient after sand filling, pressing the upper press mould down on the moulding sand inside the core box under the guidance action, micro-shocking or pressing the upper press mould to buckle it on the sticking-off surface, and proceeding to press down to make the basic surface of the upper press mould adhere closely to the core box top surface, wherein the inner cavity shape of the upper press mould is the curve part to be pressed out, i.e. the shape of the sand core top; C. the overturning and stripping step: after the basic surface of the upper press mould adheres to the core box top surface, reinforcing the core sand intensity, and overturning the upper press mould and the core box under a tightly locked condition, then stripping with the core box lifted and the sand core enclosed by the loose pieces which are just disposed on the basic surface of the upper press mould; D. the step of withdrawing the loose pieces: taking out the loose pieces by sliding along the basic surface of the upper press mould; E. the sand core hardening and coring step: the sand core to be made is supported by the upper press mould after withdrawal of the loose pieces, and carrying on painting and cleaning when it is hardened to a required intensity.
 2. The one-piece core-making method for railway truck bolster and side frame according to claim 1, characterized in that the compression strength of the core sand in step B before the upper press mould is pressed down is less than 0.04 MPa, and after the basic surface of the upper press mould adheres to the core box top surface, the mould can be stripped when the compression strength of core sand is more than 0.06 MPa. 